Connector With Multi-Directional Press-Fit Contacts
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Solution Overview
Problem
Connectors with floating structures face issues where applied stresses can shift the supporting position of contacts, leading to loose connections or contact dislodgment, and similarly, contacts fixed by solder on circuit boards can experience stress-induced cracking.
Innovation Solution
The connector design incorporates contacts with first and second press-fit portions that protrude oppositely in different directions, which are press-fit into the housing, maintaining the relative position between the housing and contact even under various stress applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a contact is held by a housing with a simple press-fit structure, then the ease of manufacture is improved, but the reliability deteriorates when various stresses are applied to the contact
Solution Approach 1:
The contact structure employs asymmetric press-fit portions with different orientations (first press-fit portions in a first direction, second press-fit portions in a second direction perpendicular to the first direction). This asymmetric multi-directional configuration allows the contact to resist stresses from multiple directions simultaneously, resolving the contradiction between simple manufacturing and high reliability under various stress conditions.
Solution Approach 2:
The invention transitions from a single-direction press-fit structure to a multi-dimensional press-fit structure by adding press-fit portions in perpendicular directions. This dimensional expansion enables the contact to maintain reliable connection with the housing even when subjected to stresses from multiple directions, while still using a relatively simple press-fit manufacturing process.
2Adaptability or versatility
If a connector has a floating structure allowing movable housing movement, then the adaptability is improved, but the stability of the contact supporting position deteriorates when stresses are applied
Solution Approach 1:
The contact is segmented into multiple functional portions: first press-fit portions for primary positioning, second press-fit portions for secondary positioning in perpendicular direction, and an SMT portion for circuit board mounting. This segmentation allows each portion to handle specific stress directions, maintaining contact stability even when the housing moves in a floating structure configuration.
Solution Approach 2:
The multi-directional press-fit portions create an asymmetric reinforcement structure around the contact-housing interface. This asymmetric multi-axis constraint system provides enhanced stability to the contact supporting position while allowing the overall floating structure to adapt to misalignments through controlled movement.
3Force
If stresses are applied to a solder-fixed contact, then the force transmission is improved, but the harmful effect of solder cracking increases
Solution Approach 1:
The press-fit portions act as intermediary mechanical anchors between the contact and housing, providing additional force transmission paths that do not rely solely on the solder joint. By distributing mechanical stresses through multiple press-fit contact points in different directions, the solder joint is protected from concentrated forces that would cause cracking.
Solution Approach 2:
The multi-directional press-fit structure provides preemptive mechanical support and stress distribution before stresses reach the solder joint. This prior cushioning effect through distributed press-fit contact points prevents excessive force concentration at the vulnerable solder connection, reducing the risk of solder cracking under applied loads.
Data Source
AI summary
A connector comprises a housing and a plurality of contacts. Each of the contacts has one or more first sets and one or more second sets. The first set includes two first press-fit portions which protrude oppositely to each other in a first direction. The second set includes two second press-fit portions which protrude oppositely to each other in a second direction perpendicular to the first direction. The first press-fit portions and the second press-fit portions are press-fit in the housing.